mitsubishi freqrol f2 service manual

7/25/2019 Mitsubishi Freqrol F2 Service Manual

1/128

ll

version

MITSU IS I

l TRI


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CONTENTS

1. SCOPE OF MANUAL

3. STANDARD SPECIFICATION

2. BASIC CONCEPTIONS ABOUT THE INVERTER OPERATION

4

5

3.1

208/230V

AC Series 5

3.2

460V

AC eries 6

4. CONSTRUCTIONS

5. SELECTION OF THE INVERTER

4.1 Outlooks 7

11

6. MAIN CIRCUIT DESCRIPTIONS

5.1 Output Rating of the Inverter 11

5.2 Start ing Torque and Starting Current

of

Motor

13

5.3 Acceleration/Deceleration Time 14

5.4 Selection of Brake Unit 17

22

6.1 Converter Module 22

6.2 Initial In-rush Current Suppress Resistor and Contactor 23

6.3 Main Circuit Capacitor (Smoothing Capacitor) 25

6.4 DC Current Transformer (DC-CT) 27

6.5 Transistor Module (Transistor Chopper) 29

9. FUSING

7. CONTROL CARD

11 RADIO INTERFERENCE NOISE

10

POWER FACTOR IMPROVING REACTOR

8. SOME OPERATION PRINCIPLES OF THE TOTAL SYSTEM OF THE INVERTER

32

7.1 Card Application 32

7.2 BasicOperation of the Control Card

7.3 Fault Indicating Lamp 35

36

8.1 Stall Prevention , 36

8.2 Electronic Thermal Relay , 38

8.3 Ground Fault Protection , , .40

, 41

. 42

43 m

11.1 Propagation Path

of

Noise .43

11.2 Noise Measuring Method .43

11.3

easures

Against Radio Noise .44

11.4 The Type and Outl ine

of Filter

.45

1


4/128

12 .

APPLICATION OF INVERTER

. .

.

46

m

12.1 Eff iciency and Heat Generation Amount of Inverter .46

12.2 Heat Generation

Amount of

Inverter and Cooling of Panel .47

13. WIRING

49

13.1 Wiring Diagram. , .49

13.2

Input/Output

Terminals, , . , . 50

13.3 Terminal Arrangement , , , 51

14. MAINTENANCE AND CHECKING

. . . .

54

14 1

Measuring Methods fo r Voltage and Current of Various Parts 54

14.2 Cause

of

Protective Function Working and Countermeasure , 56

14.3 Troubleshooting 58

14.4 Investigation of Parts in p.c.b , . 71

14.5 Periodic Checking

.

79

14.6 Checking up

of

the P.C.B. and Normal Waveforms 80

19 . DRAWINGS_

18.

SPARE PARTS

17 . TROUBLE CALL

15. REPLAGEMENT OF THE PARTS

16 . SOME MISCELLANEOUS INFORMATIONS

93

m

15.1 General

.

93

15.2 Replacement

of

the Printed Circuit Board FRF2-CB(A) and FRF2-DR 95

15.3 Smoothing Capacitors , 98

15.4 Diode and Transistor Modu les , 100

15.5 Cooling Fan (Ventilator) , , 101

15.6 DC-CT (DC Current Transformer) ..

. .

, 102

15.7 Operat ion Panel 103

104

16.1 To Changethe Rated Power Supply Voltage

from

230V into

208V Vice Versa 104

, 105

m

17.1 Confirmat ion Items at Trouble Call f rom Your Customer 105

107

114

19.1 FR-F2-750Band 1500B 114

19.2 FR-F2-750throu. FR-F2-3700 115

19.3 FR-F2-5.5K and FR-F2-7.5K ,

. .

116

19.4 FR-F2-11K throu. FR-F2-30K

. .

.117

19.5 FR-F2-37K , 118

19.6 FR-F2-45K and FR-F2-55K 119

19.7 FR-F2-H3700 throu. FR-F2-H7.5K 120

19.8 FR-F2-H11K and FR-F2-H15K ,, 121

19.9 FR-F2-H22K 122

19,,10FR-F2-H30K throu. FR-F2-H55K. 123

2


5/128

S OP OF M NU

S OP

OF MANUAL

The scope

of

this manual is to explain the basic idea about the operation of the inverter trouble

shootings and parts replacements Some pictures which show the appearance of the inverter and

waveforms and drawings are included

We hope

that

this manual is helpful fo r you

to

service and maintain our products

CAUTION

READ THISM NU L

REFULLY

BEFORE STARTING THE CHECKING UP OF

THE INVERTER

2 DISCONNECT THE

POW R

SUPPLY BEFORE THE INSPECTION OR THE RE-

PLACEMENT OF

NY

PARTS

3 W IT FOR A WHILE UNTIL THE CHARGE INDICATING LAMP GOESOUT

4

ONLY

THE ELECTRICAL PERSONNEL SHOULD BE ALLOWED TO CHECK

ND

INSPECT THE INVERTER

3


6/128

2

SIC CONCEPTIONS OUT THE INVERTER OPER TION

2

SIC CONCEPTIONS OUT THE INVERTER OPER TION

The FR-F2 inverter made up of the converter, the inverter and the control

circuit

as shown in

Fig, 2.1

FR-F2

converter

r - - -

R

3 phase I

power supply S } - - - . , . - - - - -

L J

smoothing capacitor

inverter

r ...

_ _ _ _ _ _

control circuit

F ig 2 1 FR F2

Main Circuit Constructions

The three phase

AC

power supply is recti fied

into

DC voltage

by

the converter diode module) and

smoothed by the smoothing capacitor. This DC voltage is chopped and modulated into PWM pulse

width modulation AC voltage by the inverter transistor module)

but

its frequency is

different

from

the one of the

input

power supply. That

output

frequency is controlled by the control circuit

in the printed

circuit

board.

In the case of the induction motor, the rotor speed N rpm) is given by the following formula.

N rpm)

120f l -s

P

where,

f: given frequency

p:

number

of poles

s: slip of

rotor

For

example, when a 4-pole

motor

is driven

by

the

60Hz

power supply and

i f

the

rotor

slip is 5 ,

the

motor

will

rotate at the speed

of

N= 12060 1-0.05 = 1710rpm

4

4


7/128

3.

ST ND RD SPE IFI TION

m m r n r n r n ~ F

3. ST ND RD SPE IFI TION

3.1

208/230V

AC Series

t ~ y p

FR-F, 75OB-U (750-UI

FR-

1500B-U

FR-F,

2200,,U

FR-F,-3700-U

FR,F,-5,5K U

FR-F,-75KU

F, -

(1500-UI

Nominal

output

(HP)

1/ 2

I

1

2

3

5

7..5

10

c

.;:

Output

capacity (kVA) 2,0

3, 2

6,,8

9,,6

13.1

:l

Rated

output

current

(A) 5 8 17 24 33

\.

::l

3-phase, 208V AC or 230V AC (*1)

Max

output

voltage

Power source

requirement

(kVA)

2_5

4

5

5_5

9

12

17

Weight (Ibs.) 9, 9

11

13.2

18,7

19.,8

Construction

Enclosed

type (I

P20)

Voltage

/frequency

3-phase

208V

AC or

230V

AC 60Hz

'->-

Permissive voltage regulation

208V

10

or

230V

10

l

ot \

Permissive frequency

.; l

60Hz 5

regulation

I

Item Type

FR-F,-llK-U

FR,F,-15K-U

FR-F, -22K U FR-F,-30K-U FR F,

-37K-U

FR-F,-45K-U

FR-F,-55K U

Neminal

output

(HP) 15 20 30 40 50 60 75

e

;::

Output capacity

(kVA)

18,3

24.3 36

46

58

70

86

::l

Rated output current

(A)

46

61

90 115 145 175

21 5

,

::l

Max.

output

volt g

3-phase, 280V AC or

230V

AC

(*1 )

Power source reqirement (kVA)

20 28 41 52

66

80

10 0

Weight

(tbs.)

44.,1

55,,1

66..1

88,2

132,3 1543

1 7 6 4

Construction

Open

type lPOO

Voltage/frequency

3 -phase , 208V AC or 230V AC

60Hz

-> -


208V 10 or

230V

10

l

o t \

Permissive

frequency

.; l

60Hz

5

regulation

Note: *1 )

the source voltage drops the output voltage larger than the source voltage is no t guaranteed

Common specifications

Item

Description

Control

method

Sinusoidal PWM,voltage

control

Frequency range

6 to

50Hz/6

to

60Hz

selectable (Operat ion starts at 3Hz, Frequency upper

limit is provided.)

Frequency resolution

025Hz (OJ 25Hz only in acceleration/deceleration fo r models larger

than

5..5K)

c:

o

+:

to

u

u

Ql

Ii

e

e

8

Freqnencv

accuracy

Voltage/frequency

ratio

Overcurrent capacity

Frequency setting signal

Acceleration/deceleration

time

Select ab le in 4

s te ps t wo

steps each for normal

torque

and reduced

torque)

150 f or o ne

min,

oto 5V DC, 0 to 10V

DC/4

to

20mA

selectable.

0.2-3.0 sec

lin

0. 2

sec

increments),

1 -1 5

sec, l in 1 sec. increments),

10-150

sec

lin 10 sec increments) selectable

Regenerative braking

torque

Approx. 20 of rated

mo tor to rqu e

Protective

function

Protection against stalls caused by overcurrent,

protection

against stall caused

by regenerative overvoltage, overcurrent protection, regenerative overvoltage

protection,

overload protection (electronic thermal relay), instantaneous

power failure protection,

thermo

detect of th e heatslnk, ground fault protec

tion

at load side (*2)

Ambient temperature

14 F to 12 2

0

F (to be free from freezing)

Less

than

90

to

be free from condensation)

Below

3,000

ft above sea level

Less

than

O..5G

To be free

from

corrosive gases and dense

dust

tmosphere

Altitude

Vibration

Ambient humidity

to

: c:

E

8 f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - /

w

Note:

*2 )

FR-K- 5.5K-U or higher

mo el

equipped with thermo ete t of the beetsink

5


8/128

3 STANDARD SPECIFICATION

3

6 V

AC

ri s

Item

Type

FR-F

z-H3700-U

FR-F

2 -H 5 , 5K -U

FR-F

z

-H7,,5K-U FR-F

2 -H 1 1K -U

FR-F

2 -H 1 5K -U

Nominal output (HP) 5

7,,5

10

15

20

... .

:0 I:

Output

capacity

(kVA)

7,,2

9,6

13,,5 18,,3

24,,7

.,_

:0

Rated output current (A)

9

12

17 23

31

Max

output

voltage 3-phase,

460V

AC (*1)

Power source requirement (kVA) 9

12 17 20

28

Weight [lbs.]

18,7

264 264

59,5

59,,5

Construction

Enclosed

type

(lP20)

Open type (I POOl

Voltage/frequency

3-phase, 460V AC

60Hz

~

-


:a .

460V 10

oa .

c.

:0

Permissive frequency regulation

60Hz

5

Model

FR-F

2

-H22K-U FR-F 2 -H30K-U

FR-F

2

-H37K-U

FR-F

z

-H45K-U

FR-F

2 -H 5 5K -U

Nominal

output

(HP) 30

40 50 60

70

Output

capacity

(kVA)

34 45 56 69

88

a.,,_

......

Rated

output

current

(A) 43 57 71 87

110

:0

Max.,output voltage

3-phase, 460V AC (*1)

Power source capacity (kVA)

41 52 66 80

100

Weight

(Ibs.)

70,,5 143,,3

143,3

1874 1874

Const ruction

Open type (IPOO)

Voltage, frequency

3-phase, 460V AC 60 Hz

~

-

: a.

Permissive voltage regulation 460V 10

oa.

Permissive

frequency

regulation

60Hz

10

Note:

0

the source voltage drops the

output

voltage larger than the source voltage is

no t

guaranteed

Common specifications

Item

Control method

Frequency range

Description

Sinusoidal PWM, voltage

control

6

to 50Hz/6 to 60Hz

selectable

(Operation starts

at 3Hz

Frequency upper

l imit is

provided.

0..25Hz

(0,125Hz only

in

acceleration/deceleration

for models larger than

55K)

0,,5 (77F 18F)

Selectable in 4

steps

( two steps each fo r normal torque and reduced torque)

150

fo r

one min,

Regenerative braking

torque

o

to 5V DC, 0 10V DC/4 to 20mA selectable,

0.2-3.0

sec (in 0.2 sec,

increments),

1-15 sec, (in 1 sec

increments),

10-150 sec (in

10

sec, increments) selectable

r ~ ~ ~ t

Approx 20 of

rated

motor

torque

:1 :

0

E ; ;

1 : -

0 0

I:

- 0

E

w

Protective

function

Ambient temperature

Ambient

humidity

Atmosphere

Altitude

Vibration

Protection

against s ta ll s caused by

overcurrent,

protection against stall caused

by regenerat ive overvoltage, overcurrent protection, regenerative overvoltage

protection, overload protection (electronic thermal relay), instantaneous

power failure protection, thermo detect of the heatsink, ground fault protec

tion at load side (*2)

14

0

F

to

122

0

F

(to

be free

from

freezing)

Less than 90 (to be free from

condensation)

To be free

from

corrosive gases

and

dense dust

Below 3,000 ft above sea level

Less than

0,5G

Note:

(*2)

FR-K-5 5K-U or higher

model

equipped with

thermo detect of

the heetsink.

6


9/128

4 CONSTRUCTIONS

4 CONSTRUCTIONS

4 Outlooks

FR F2 inverter series has

two different

kinds of construct ion. One is the plastic cover

type

and

another is the steel box type. These

two

types

of

FR F2 are used in the

following

manner.

From 1HP up to 10HP Plastic cover type

From 15HP up to 75HP Steel

ox type

I

a Plastic cover

type

8843 76 5

b Steel cover

type

Fig. 4.1 Outlooks of FR-F2 Inverter

8843 91 5

rom view

po in t o f

internal construct ion the FR F2 inverter is div ided

into two

series one is

FR F2 750B U FR F2 1500B U and all other F R F2 s ri s These construct ions are shown in

Fig. 4.2, Fig. 4.3 and Fig. 4.4.

7


10/128

CONSTRUCTIONS

8843 92 7

Plastic cover

Chasis

_ Printed circuit board

I

I

I I

I

I I

I I

I -,

I

I

I

I

I

I

I

I

I

I

-

I

I

I

Fig. 4 Internal View of Plastic Cover Type FR-F2

(

FR-F2-750-U through 7.5K-U )

and H3700-U

through H7.5K U


11/128

4. CONSTRUCTIONS

I

8843079-7

8843079-5

8843082-1

hasis

;; 1; 1---

Steel cover

I

I

I

I

I

I

I

I

II

I I

I I

I

I

I I

I I

I

l c

I

I

I

I

I I I

I

I

I I

I I I I

I I I I

I

L-I-I-

I

l

L I L..

- -

L

I .J. ; l

1

Cooling

fans _

Printed circuit board

Control

circuit

Fig. 4.3 Internal View of Steel CoverType FR F2

FR-F2-11

K U through 55K.U

and H11K U throu H55K U

9


12/128

CONSTRUCTIONS

8854175 1

8854175 3

8854175 5

Plastic cover

Chassis

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

r

J

J

I

I

I

I

I I

\ \

\ t

1

I

I I

I

Fig 4 4 Internal View of FR F2 750B U and 1500B U


13/128

5

S L TION OF TH INV RT R

5 S L TION OF TH INV RT R

5.1 Output Raitng of the Inverter

The

output

capacity

of

inverter is calculated on

the

basis

of

rated

output

current value.

inverter output capacity

kVA

=

x maximum output voltage V) x rated output current ) x 10

The

rated output

current

is the

current

value which the inverter can be continuously operated at the

rated output voltage, and it is always required to use the inverter below or at thi s current value.

When

current

more than the rated

output

current of inverter flows, overcurrent resistance

amount

is

determined as an allowable value. This amount is generally 150 rated for one minute fo r general

purpose inverters. However, i t is sometimes 120 one

minute

for

inverters

for

pumps and fans. At

the

time of starting or instantaneous overload, i t is required

to

use the inverter below this value.

The capacities of general-purpose inverters are classified by

the

rated capacity kW)

of

motor.

However,

this

output

capacity applies

to

the

c se

where one general-purpose squirrel-cage

induction

motor with two to six poles is operated without special restriction on starting time or start ing

torque. When a special motor or multiple

motors

are operated in parallel by one inverter, or when

an operation pattern or load torque is specified, i t is required to select an inverter with capacity

proportional to the condition.

5.1.1 Operation

of

one motor

Select a capacity

which

meets

the

following condition:

Inverter rated output current motor rated current

5.1.2 Operation of multiple motors

Select a capacity which meets the following condition:

nverter rated output

current

total of rated currents of simuItaneously-operated motors I

However, when several motors are directly started in succesion, it is required

to

select a capacity

so

that

total of

input

currents to motors, including the starting

current

at

the

time of

direct

start,

may

be lower than the overcurrent resistance amount of inverter, and in actuality an

extremely

large capacity is required for

the

inverter. In this c se i t is

often the c se

that installation of an

inverter

for

each

motor

results in lower cost,

11

I


14/128

5.


5.1.3 L ig ht m o to r load

When load is

extermely light in relation to the rated torque of the operation motor,

motor

current

great ly reduces as compared to rated current. Therefore,

lo w

cost may be achieved

by

the

application of

inverter with small output capacity as compared to

motor

capacity. However, the

following precautions must be taken

fo r

determining the output capacity:

In the general-purpose inverter, exciting

current

of

30

to

50

of

motor

rated

current flows

even at

no load. Fo r this reason, an inverter with extremely small output capacity cannot be used.

A t light

load, even

if

an effective

current

value is equal, the ripple rate of

current

is larger as

compared

to that

at the time of rated load. In a transistor inverter, since protection against

overcurrent is provided by detecting instantaneous crest value

of

motor current, overcurrent stall

prevention protective function is activated at the crest value due

to

ripple even

i f

effective current is

small. Therefore,

i f

the

motor

is started, speed is

no t

increased, or an overcurrent protective

function

is activated, resulting in failure such as

motor

stop. Fig. 5.1 shows the input current

waveforms of

tw o

types (30HP and 10HP)

o f

motors which are driven by the sine wave PWM type

inverter. Even i f

th e

30HP

motor

has light load and is equivalent in rated current to th e 10HP

motor,

th e input current

r ipple and

current

crest value of 30HP

m ot or w it h

l ight load are larger

than those of th e rated

current o f

10HP

motor

as shown in Fig. 5.1

hltc},

As described above, th e

output

capacity

of

inverter

cannot

be

extremely

reduced even at l ight load.

Fo r

the transistor

inverter, the capacity of inverter is basically determined depending on

that

of motor. In light load

operation, however,

it

is possible to reduce the capacity

to that

of an inver ter which is smaller

by one rank, by considering operating conditions, such asstarting conditions.

(a)

30HP (4P)

rated load

JlI

III ..

IIMlNJ

~

...,

J

(b) 30HP (4P) light load

.J

L. J

r I

IL

-,

lw J

r

M

II

(e)

10HP (4P)

rated load

17 A

Fig, 5.1 nput Current of Motor [25A/div., 5ms./div.l

12


15/128

S L TION OF THE INV RT R

5.2 Starting

Torque

and Starting

Current

of Motor

When a general-purpose

motor

is directly started by commercial power source, starting

current

six

to

seven times as large as motor rated

current

flows and also motor starting

torque

1.5 to

5

times

as large asrated

torque

can be obtained.

However, the starting and accelerating characteristics

of motor,

which is combined with an inverter,

are restricted by the

current

characteristics

of

the combined inverter, and therefore, are

different

from

those in

direct

start ing by commercial power source. In other words, since the motor is

accelerated with

current

at the

time

of motor start and acceleration kept lower than the current

l imit level of inverter generally,

150

of rated current , starting torque and accelerating torque

are smaller than those of

direct

start by commercial power source. Fig.

5.2

and

5.3

shown examples

of speed vs

torque

and

current

characteristic curves of general-purpose motor. When the motor is

combined with a rated-capacity inverter, the torque at speed corresponding to the intersecting point

with the

150

current value rated current reference of inverter) and the current characteristics of

each f requency is the

maximum

torque short-t ime rating) generated by the motor .

The

starting

torque at the speed of 0 rpm is 110 point in the example below.

When the capacity of inverter to be combined is increased by one rank, the star ting torque and

maximum torque increase, as shown in Fig 5.2, proportional to the increase of

current

l imit level.

When

the

starting

torque

and

maximum

torque

are insufficient, the increase

of

inverter capacity

by one rank is one of effective methods.

I

FR-F2

with

I capacity

I improved

one

I rank

_

I

FR-F2

with

rated capacity

60Hz

1800rpm

50

1500

600

500

400

c

C l

8 : ~ i : ~ _

o 3 6 10 15 20 30

o

900

60Hz

100

torque

1800rpm

50

1500

30

900

230V

60Hz

TEFC

10HP 4P

FR-F2-7

5K-U

. . . . . . ~

280

Fig. 5.2 Speed vs

Torque Curve

Fig. 5.3 Speed vs. Current Curve

Since motor torque changes in proportion to the square of voltage, it is inf luenced by the output

voltage

of

inverter. In Model FR-F2 and

FR-K

inverters, when

the

input

voltage line voltage)

of

inverter reduces, the output voltage

may

sometimes reduce

slightly,

resulting in decreaseof starting

torque. The starting current

of

motor also reduces.)


16/128


5.3

Acceleration/Deceleration

Time

To

hold the star ting current of

motor

to within the overcurrent resistance amount of inverter, the

motor

is started at 3Hz without regard

to

the capacity and type of inverter, and the

output

fre

quency of inverter is gradually increased in increments indicated by frequency resolution When the

motor is decelerated from the preset frequency

by

the inverter,

the

output frequency

of

inverter is

gradual ly decreased in order

to

prevent excessive direct-current bus voltage

of

inverter due

to

regenerative energy from

the

motor. For such reasons, when the motor is accelerated and de

celerated by the inverter, i t is required

to

set

the

acceleration time and deceleration time of output

frequency ranging from zero to maximum frequency.

5.3.1 Setting

of

acceleration time and deceleration time

Acceleration time or deceleration time should be set longer than the acceleration

time

or decelera

tion time determined from the motor torque, load

torque

and iner tia inherent in the motor and

load G02 or WK

2).

When acceleration time is set

too

short, overcurrent (OCT) protection circuit is activated, causing a

tripping of the inverter. When deceleration

time

is set too short, overcurrent (OCT) or regenerative

overvoltage

OVT)

protection

circuit

is activated, causing a

tripping

of

the

inverter.

5.3.2

Calculation of acceleration, time and deceleration time

N

Operation speed

Nb

ta

Acceleration time Deceleration time

Na_

t 1

Fig 5 4

Setting

of

Acceleration Deceleration

Time

(1) Simplified calculation formula of acceleration and deceleration

time

2 2

Acceleration

time

t GOT x

4lN

(sec) or

WKT

x

4lN

. (sec)

375

x (TM X a -

Tt.max) . 1230

x (TM x a -

Tt.rnax) .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5.1)

2

GD2 x.4lN WKT x

4lN

Deceleration time tS = 375 x (TM x f + TLmin) (sec.) or

1230

x (TM x f +

Ti.rnin)

(sec.)

(5.2)

2 2 2

where GD

2

(WK

2):

Total

GOT WKT)= motor

G0

2

(WK

2)

+ load GO (WK

2)

(value converted into

motor

shaft torque)

G0

2:

kq-rn , WK

2

.lb-ft. . m ft . in diameter)

.4lN: difference in

motor

speed before and

after

acceleration/deceleration Nb - Na (rpm)

TM : motor rated

torque

974xP

5250xHP

TM = N (kq-rn)

or

TM = N

( lb.vft .)

(5.3)

Ti.rnax: maximum load torque (converted into motor shaft torque) (kq-rn)

Tt.rnin: minimum load torque (converted into

motor

shaft torque) (kq-rn)

a: mean acceleration torque

coefficient

f

mean deceleration

torque coefficient

(regenerative

torque

coefficient)

P: motor output (kW)

HP: motor output (HP)

N:

motor

rated speed (rpm)

4


17/128

I

SELECTION OF THE INVERTER

FR-F

2

FR-K

Torque Ratio

V/F = CONST, V/ F =

REDUC,

6 to

60Hz

60 to 120Hz

a

11

0,,9 1 ,1

0,77

Short

time

0.7

Short t ime 0,46

fo r

FR-K-11k

0.13

for

FR-K-11k

Without brake

unit

0.,2

and models

with

and models with

larger capacity

larger capacity

and

400V

class

and

400V

class

With

brake

unit

retarding torque:50 )

5

0 5

0.,5 033

With brake unit

1,0

1.0

1.,0 067

(retarding torque:1 00 )

Table 5 Acceleration Deceleration Torque Rations with Standard Combination of Motor Inverter and Brake Unit

Note

1m = 3.28ft

1kg = 2.205Ib.

Note

Set the interval the ACCEL/DECEL d ia l t ime f rom zero to

maximum

output frequency of inverter.

Therefore, set a value which is larger than the above calcu la ted value

of

acceleration/deceleration time

x maximum speed/AN

1kgm

2

= 22051b. x

3 28ftP

= 23..72Ib, ft.

2

I WK

2

Ib. tt

2

= 23 72 X GD

2

kg.m

2

(m it is

by

diameter)

GD

2

kg.m

2

=

00422

X WK

2

(lb .ft

2

1kgm =

2.205Ib

x

3 28ft

= 7.23Ib.ft

1:I

Torque

(lb.dt.]

=

7 23

x Torque kg,m)

Torque

(kgm) =

0.138 x Torque (tb.dt.]

1kW=0.75x HP

15


18/128


2) Calculation and setting

of

acceleration/deceleration

time

Calculate and set the accelerat ion and deceleration times, independent

of

frequency range

applied, as follows:

a) When the maximum frequency is

of 60Hz pattern, calculate

t

and tS2 from the expres

sions 5.1) and 5.2) using

0:

and

fo r

frequency range 6

to

60Hz, determined

from

Table

5.1 and Na = 0, Nb = nOO/number of poles.

With calculated results, set the ACCE LlDECE L dial as fol lows:

Acceleration

t ime> t

Deceleration

t ime> tS2

. 5.4)

. .

.

. .

5,,5)

For bet te r response, set the

time

as short as possible

within

the permissible

range

When

gradual acceleration/deceleration is required, set the required time.

r--Exannple------------------- .- .------------------------------------- ,.--------------------------- ,

When ODP 5HP 4P

motor

and FR-F2-3700-U inverter

without

brake

unit

are used to drive a

conveyor under the following conditions, determine the acceleration and deceleration times as

follows:

. 2 2 2 2

In this case GDM = 0.062kgm

2

WKM = 1.47Ib.f t.

2

GDL = 0,,15kgm

2

WKL= 3.56Ib.ft.

2

Ti.max = 1.5kgm 10,,85Ib.ft.), Tt .rnin = 1.2kgm 8.68Ib. f t. ), and set acceleration and de

celeration times asshort as possible.

5250

x 5

= 1750 = 15.0Ib.ft.

2

WKT = 1.47 + 3,,56 = 5.03Ib.ft.

2

5.03 x 1800

t

= 1230x

15x

1.1

-10.85

= 1.3sec.

5.03 x 1800

tS2

= 1230 x 15 x 0.2

+

8.68) = 0.63sec.

1.33sec.

0.63sec.

tS2

375

x 2.06 x 0.2 + 1.2)

2

G DT = 0.062 + 0.15 = 0.212kgm

2

AN = Nb - Na =

-

0 =

1800rpm

4

TM

974 x 3.7 = 206k .

1750 . g m

Let

a = 1.1 and

= 0.2,

t

=

0.212

x 1800

375x

2.06 x 1.1

-1.5

0.212 x 1800

Thus, set the acceleration

time to

2sec. and the deceleration

time to

1sec..

16


19/128

TL Ib. f t. )

5. SELE TION OF

T

INVERTER

5.4

Selection

of

Brake

Unit

To shorten acceleration time, increase

the

capacity of inverter and also the capacity

of

motor. To

shorten deceleration time, add a brake unit option .

To decelerate a motor by an inverter, gradual ly reduce output frequency at the deceleration time

set by the DECEL dial which is also used as an

ACCEL

dial in the

FR-F2

series). When an

attempt

is made

to

decelerate

the

motor

at an interval

of

time

shorter than the

motor

coast-to stop

time,

the

motor

acts as an induction generator because

it

is rotated at over synchronous speed of

given frequency. Therefore, its

rotating

energy is

partially

consumed by the motor

winding

and

partially accumulated in the capacitor

of

inverter. The brake unit s v s to absorb this energy.

The energy is consumed by the discharging resistor, and as a result, the braking action of

motor

is

obtained. in Table 5.1 indicates a brake torque

ratio

at the

time of

deceleration in relation

to

the

rated

torque of

motor.

5.4.1 Selecting procedure of type BU brake unit

Brake

torque

is no t manually adjustable in

the

brake unit However, when

the

brake unit is com

bined with

the

inverter, the setting of required deceleration pattern with DECE L dial) allows

the

motor to be decelerated with the brake torque

automatically

adjusted.

The brake unit suitable fo r individual applications can be determined as follows:

) Calculate brake torque necessary to decelerate in the deceleration pattern selected

T

- GD

2

N1 - N T k ) T _ WK

2

. N1 - N2

B - 375t - L gm or B - 1230t

) Perform the

following

calculation to knoVli how much percentage is the calculated TB in

reference to the rated

torque of

motor used.

TB

Brake torque )

=

TM x 100

3) Select a brake unit, of which intersecting point

of

brake torque ) and deceleration time t)

exists below the characteristic curve of the motor used, from brake unit data.

r Example - - - - - - - - - - - - - - - - _. - - - - _. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - _. - - - - - - - - - - - - - _. -_. - - - - -

--

It is desired to decelerate from 1,750rpm to Orpm in two seconds by use of a 5HP 4P

motor

under

the following conditions:

Load

torque

converted to motor shaft

torque :

10

of

motor torque

=

0.2 kgm)

= 1.4 lb.ft.

Load GD

2

converted to motor shaft

torque :

10 times

of

motor

GD

2

=

0.73 kgm)

orWK

2

=

17.3 1b.ft.

2

Motor rated torque: 5HP 4P =2

03 kgm) = 14.7 1b.ft.)

Then, the brake unit requires brake torque obtained by the following expression:

I

TB

=

.073 + 0.73) x 1750 - 0) _ 0 2

375

x 2 .

=

1.67 kgm)

TB

=

1 .73+17.3 x 1750-0 _1

1230 x 2

= 12.1 lb.ft.

Brake torque ) = x 100 = x 100 =83 ) or x 100 =82 )

_

17


20/128


Therefore, 83 brake torque is required. Since the motor is stopped in

two

seconds, the BU-3700

brake

unit

can be selected fo r this application because

of

the -braking capacity

of

BU-3700,

8 seconds in continuous, which is longer than 2 seconds.

From the repeating

duty

cycle capability which is shown in Fig. 5.6, the BU-3700 brake

unit

can

be used by 9 duty cycle.

T2 = ; X 100

=

9, T2

=

sec

Thus T1

=

100/9

x 2

=

22.1

sec

Repeated braking is possible once in 22.1sec.

In addition to this calculation, the motor should be examined if it can withstand the repeated duty

TB: Brake torque = 1.67kgm or 12

t lb.f t .

TL:

Load torque

=

O kgm or 1Alb.

TM:Motor

rated torque

=

2 03kgm or 14.7Ib.:ft.

1750rpm

Speed

rpm)

N1

r - - - -

N2 Orpm) - -

_

I T2 = 2sec l

Time

Fig. 5.5 Speed vs.

Time

Curve at Brake Unit

18


21/128


VOLTAGE

~ P

1

I

2 3

I

5

7.5

I

10

15

I

20

Torque

200V

50

30 sec BU-1500 BU-3700

BU-7 5K

BU-15K

Series

100

30

sec

BU-1500

I

BU-3700

BU-7 5K

BU-15K

2 x BU-15K

460V

50 30

sec

BU-H7.5K BU-H15K

Series

100

30

sec

BU-B7 5K BU-H15K BU-H30K

VOLTAGE

~

30

I

40 50

I

60

75

Torque

200V

50

30

sec

2 x BU-15K

3xBU-15K 4xBU-15K

Series

100

30

sec

3 x BU-15K 4 x BU-15K 5xBU-15k \6xBU-15K

7 x BU-15K

460V

50

30 sec

BU-H30K

2 x BU-H30K

Series

100

30

sec

2 x BU-H30K

3 x

B U H 3 0 1 ~

4 x BU-H30K

2 x

=

two

units areconnected parallel.

Table 5.2 Type

of

Brake

Unit

Brake

unit

Dischargeresister

Quantity

of

Specification

of

resistor

Wire

series

connection

BU-1500

300W

50 Q

1 OGZ1S 300W 50 Q

AWG

14

BU-3700

300W

10 Q

3 ORGZ1 B 200W 10 Q AWG 14

BU-7 5K

450W

5 Q

4

ORGZ1 B 300W 5 Q AWG 12

BU-15K

600W

2 Q 6 ORGZ1 B 400W 2 Q

AWG

12

BU-H7 5K

300W

10 Q

6

ORGZ1B 200W 10 Q

AWG 14

BU-H15K

450W

5 Q

8 ORGZ1 B 300W 5 Q

AWG 12

BU-H30K 600W

2 Q

12

ORGZ1 B 400W 2 Q

AWG 12

Table 5.3 Type

of

Brake Resistors

I


22/128


BU 1500 Short

time

rating BU-3700 Short t ime rating

BU-7..5K Short time rating

200V series)

200V

series)

200V

series)

100

3HP

2HP lHP

1/2HP

100

5HP

100

'0

80

'0

80

80

3HP

c

'g

i

60

i

60

i

60

E

E

E

'

40

'

40

40

c:

c:

'

.ii

30

30

c:

e

:.ii

30

ec

r

20

20 cc

20

50 100

150 200 50 100

150

Brake torque ( )

Brake troque ( )

ED

ED

5HP

3HP 2HP

ED

3HP

20

20

20

Hi

15

15

10

10

10

50

100 150

200

50 100

150

50

100

150

Brake torque

( )

Brake torque ( )

Brake troque

( )

BU-H7.,5K Short

time

rating

460V used)

100

'g

80

i

E

60

n

c;

40

30

co

20

50 100 150 200

Brake torque ( )

ED

20

15

10

50

100

150 200

Brake

torque

( )

150 200

Brake torque ( )

1HP

150 200

Brake torque ( )

100

3HP 2HP

50

40

BU-H7 5K Short

time rating

460V used)

3HP 2HP 1HP

30+----+----\-----\---+----- t - : - - t - - - -= d---- _: : : : - -

ED

80

'0

c;

i

60

E

40

'

:

30

co

20


23/128


mm[mno

BU H 15K Short time rating

(460V series)

BU H3 K

Short time rating

46 V used)

Fig. 5.6 Characteristics of brake unit

I

50 200

Brake

torque (%)

roo

50 100 150 200

Brake torque (%)

30HP

2 HP15HP

50

20+-----H:---+-+ .----+---+-

15

1 0 + - - - - + - - - . : i < : : - - - - - ~ r _ - + -

ED

100

0

80

30HP

I


24/128

6

M IN IR UIT DES RIPTIONS

L m m o o [ r r m ~

6. MAIN CIRCUIT DESCRIPTIONS

6.1 Converter Module

he function of

the converter module is

to

rectify and convert the

input

AC three phase voltage

into

DC voltage. This converter is protected from l ine surge by the surge suppressor.

R

AC three phase S

power supply

T

1

Surge suppressors

DC voltage

Fig 6 Converter ircuit

Parts used in this circuit are listed below.

Inverter type

Diode module

Surgesuppressor

FR-F2-750B-U

D20VT80 x 1

TNR23G471 x 3

FR-F2-1500B-U

FR-F2-750-U

RM10TA-H x 1

FR-F2-1500-U RM10TA-H x 1

FR-F2-2200-U

RM15TA-H x 1

TNR23G471 x 3

FR-F2-3700-U RM15TA-H x 1

FR-F2-5 5K-U PT768 x 1

200V

l ss

FR-F2-7. 5K-U PT768 x 1

FR-F2-11K-U

PD608 x 3

FR-F2-15K-U PD608 x 3

FR-F2-22K-U

PD1008 x 3

FR-F2-30K-U PD1008 x 3

BKO-C1915H02 x 1

FR-F2-37K-U BKO-C1922H01 x 1

FR-F2-45K-U BKO-C1922H02 x 1

FR-F2-55K-U BKO-C1922H02 x 1

FR-F2-H3700-U

t r u

H7 5K-U RM20TA-2H x 1

FR-F2-H11 K-U RM30-DZ-2H x 3

BKO-C1972H01 x 1

460V

l ss

FR-F2-H15K-U RM30-DZ-2H x 3

FR-F2-H22K-U

RM60-DZ-2H x 3

FR-F2-H30K-U throu H55K-U

RM100-DZ-2H x 3 BKO-C1821 H01 x 1

Table

6

Parts List of The Converter

22


25/128

MAIN CIRCUIT DESCRIPTIONS

6.2 Initial In-rush Current Suppress Resistor and Contactor

As the large capacitor is connected to the output of the converter, when the Inverter power is

turned on, large amounts of current flow into the capacitor instantaneously. To suppress this large

mout of current in such a short duration, resistors are connected between the output of the

converter and

the

smoothing capacitor.

This resistor is short circuited by

the

relay contacts soon after

the

power is on. For small size

inverters, only a relay is used in this circuit, but for larger size inverters,

the

combination of

the

relay and the on-delay timer are used.

The sett ing of this t imer is bout0.1 seconds.

3-phase

208V or 230V AC

3-phase

208V or 230V AC

R

Converter

a For inverters up to

10HP

R

Converter

Smoothing

capacitor

Smoothing

capacitor

I

on-delay

timer 0.1

seconds

b

For inverters

15HP

throu

75HP

Fig. 6.2.1 Initial Suppress Circuit for 200V class Inverter

23


26/128


MC

3-phase

6 V AC

r f

r o

R

Converter

Smoothi

capacito

-

>

L

ng

r

3-phase

6 V AC

a

Fo r

inverters

up

to 10HP

Converter

MC

R

Smoothing

capacitor

on-delay

timer 0 1

seconds

b

For

inverters

2 HP throu

75HP

Fig

6

2 2

Initial In-rush

Current Suppress

Circuit for

46 V

Class Inverter

Note: The designing criteri

fo r

this relay nd resistor is on the assumption th t the

power

on nd

o ff

is performed only few times

per

one day i.e. the cont ct of the relay

nd the power c p ility of the resistor can not e nd ur e the h ea vy duty us ge So

the power on nd

should be performedcouple

of

times per one day.

24


27/128


Inverter capacity

Relay RA)

Timer

Resistor R1)

FR-F2-750B-U TV24D1-0

MFS10N2ROK x 1

FR-F2-1500B-U

DF24D1

MFS15N2ROK x 1

FR-F2-750-U MZS15A020K x 1

FR-F2-1500-U MZS15A020K x 1

JH1A

BKO-C1967H04

Not

used

FR-F2-2200-U MFS30A010K x 1

FR-F2-3700-U MFS30A010K x 1

FR-F2-5 5K-U SA11RM-208V AC

MHS4 AOR5Kx

1

200V cl ss FR-F2-7 5K-U SA11RM-208V AC MHS40AOR5K x 1

FR-F2-11 K-U SA12RM-208V AC

FRF2 15K U

SK20-208V AC

x2

FR-F2-22K-U

SK25-208V AC

FR-F2-30K-U

SK35-208V AC

DRS-N2.AOP5

MHS40BOR5K

2 00 V AC

MHS 4088

FR-F2-37K-U

SK50-200V AC

FR-F2-45K-U SK80-200V AC

x4

FR-F2-55K U SK80-200V AC

FR-F2-H3700-U

SA10RM-200V AC

Not

used MFS30A010K x 2

throu H7.5K-U

FR-F2-H11 K-U

SA11RM-200V AC

FR-F2-H15K-U

SA11RM-200V AC

FR-F2-H22K-U

SA12RM 200V AC

MHS40BOR5K

60V cl ss

D RS-N2-AOP5

FR-F2-H30K-U

SK20-200V AC

2 00 V AC

MHS-4088

F R-F2-H37 K-U SK20-200V AC

x4

F R ~ F ~ H 4 5 K U

SK35-200V AC

FR-F2-H55K-U SK35-200V AC

ote x

1

or

x

shows the number

o

the parts used in parallelconnection

Table 6

2 Specifications of The Parts Used in The In-rush Current uppress

Circuit

6 3 Main Circuit Capacitor Smoothing Capacitor

DC voltage rectified by

the

converter issrnoothed

th e

main circuit smoothing capacitor. Ratings

and specifications for these capacitors are s o w n n t ~ Table 6.3.

Notice

that

this capacitor has its limited life

time

usUally from 3 years up

to

5 years and it depends

on the load and the

ambient

temperature

pf

th e inverter, so this capacitor should be maintained and

replaced periodical ly in every 3 to 5 years. When a capacitor is reaching to

the

end off its life t ime,

the cpacity of

the

capacitor goes down andasa resplJ the ripple of

the

output voltage will increase

which leads to

the

unstable operation of the

motor

a inverter is cont inued to be used under

this condition,

the

capacitor would result in the break down finally.

25

I


28/128


Inverter type

Type o capacitor Quantity

FR F2 750B U

BKO C1935H03

1

FR F2 1500B U

2

FR F2 750 U BKO C1935H02

1

FR F2 1500 U

1 2 ~ F

BKO C1876H08

1

FR F2 2200 U

2 4 ~ F

BKO C1876H09

1

FR F2 3700 U

2 4 ~ F

BKO C1876H09

1

FR F2 5.5K U

BKO C1876H03

2

200V

class

FR F2 7 5K U

2 4 ~ F

BKO C1876H09

2

FR F2 11K U 2

FR F2 15K U 3

FR F2 22K U 4

FR F2 30K U

32 j tF BKO C1920H01

6

FR F2 37K U

7

FR F2 45K U 8

FR F2 55K U 10

FR F2 H3700 U 2

FR F2 H5 5K U

1 5 ~ F

BKO C1944H04 4

FR F2 H7.5K U

4

FR F2 H11 K U 4

FR F2 H15K U 4

460V class

FR F2 H22K U

6

FR F2 H30K U BKO C1944H06

8

FR F2 H37K U

8

F R F 2 ~ H 4 5 K U

10

FR F2 H55K U 10

Table 6.3 Specifications

o

Smoothing Capacitor

Note: Voltage ratings are 35 V DC fo r V class and

4 V

DC for 46 V class inverter

Fo r

the

46 V

class

inverter

two

groups of capacitors are connected in s ri s

8848 98 7

Fig. 6.3 utlook o Main Circuit Capacitor

26


29/128

6. M IN IR UIT DES RIPTIONS

6 4 DC Current Transformer DC-CT

To detect the

output

current, two DC-CTs are installed in the DC-BUS circuit as shown in Fig.

6.4.1.

R

S

T

~ ~

( 1

DC-CT1 I

*

onverter

J

Inverter

DC-BUS Circuit

7

I

r

oc crz I

J J

J

J

C O ~

7

Control circuit

FRF CA

Fig. 6.4.1 DC-CT Connection Diagram

U

V

W

I

Control circuit FRF2-CA

Hybrid IC

BKO-C1921

,-----------,

15

1 ,

I

I

1

I

I

I

,

~ I

I

L .J

- - - -

; . . . . . . r . ~

_

- - -

; r

I

I

I

1

I

I

3

I

4

I

2

I

DC-CT

DC-BUS circuit

Fig. 6.4.2

Function

of DC-CT

8843085 5

Fig. 6.4.3 Outlook of DC-CT

27


30/128


The

function

of the DC-CT is to convert the amounts of the main circuit DC current

into

the DC

output voltage. The rated

output

voltage is

5 mV

at the rated current. But asthis

output

signal is

the

differential signal, it is impossible to measure this voltage directly at the output terminal

of

the

DC-CT. In the control card printed

circuit

board), the

output

signal

from

the DC-CT is connected

to the hybrid IC

type

BKO-C1921 asshown in Fig. 6.4.2. This hybrid IC functions asa differencial

amplifier

which produces the signal of

5 mV

per rated current.

At

the checking or the replacement of this part, the following percautions must be taken.

1. The DC-CT is vulnerable to the static electricity. So do

no t

touch any measuring tools,

including the multimeter to the terminal of the DC-CT at any t ime.

2. When carrying or storing the DC-CT, use the antistatic electricity container.

3.

At

the replacement, take care

to

keep the same turning number of the main circuit wiring.

For

types of this DC-CT, refer to Table 6.4.

Inverter type

DC-CT type Quantity

FR-F2-750B-U

BKO-C1977H13

2

FR-F2-1500B-U BKO-C1977H14 2

FR-F2-750-U BKO-C1909H02

2

FR-F2 1500-U

BKO-C1909H03 2

FR-F2-2200-U BKO-C1909H05

2

FR-F2-3700-U BKO-C1909H05 2

FR-F2-5

5K-U BKO-C1909H06 2

200V l ss

FR-F2-7 5K-U

BKO-C1909H07

2

FR-F2-11K-U BKO-C1909H08 2

FR-F2-15K-U BKO-C1909H09 2

FR-F2-22K-U BKO-C1909H 11

2

FR-F2-30K-U BKO-C1909H12

2

FR-F2-37K-U BKO-C1909H13

2

FR,F2-45K-U

BKO-C1909H14 2

FR-F2-55K-U

BKO-C1909H15 2

FR-F2-H3700-U BKO-C1909H29

2

FR-F2-H5.5K-U BKO-C1909H17

2

FR-F2-H7 5K-U

BKO-C1909H17 2

FR-F2-H11 K-U

BKO-C1909H19

2

FR-F2-H15K-U BKO-C1909H19 2

460V

l ss

FR-F2-H22K-U

BKO-C1909H21

2

FR-F2-H30K-U

BKO-C1909H23

2

FR-F2-H37K-U BKO-C1909H23

2

FR-F2-H45K-U

BKO-C1909H25

2

FR-F2-H55K-U

BKO-C1909H25

2

Table 6.4 Types

of DC-CT

28


31/128

6. M IN IR UIT DES RIPTIONS

6 5

Transistor Module Transistor Chopper

1 Circuit diagram

oftransistor

module

The transistor module used in the FR-F2 inverter has two kinds ofcircuit constructions. One of

them is, as shown in Fig. 6 5 1 t he t yp e which includes six transi stors in one package and

another one includes two transistors in one package as shown in Fig. 6 .5.2. The former one is

applied

to

the

transistor

type

QM15TC-H, QM20TC-H and

th e

latter

one

is applied to all

other

types of transistor.

Fig. 6.5.1 Six Transistors Type Module Applied to the QM15TC-H and QM20TC-H

Fig. 6.5,,2 Two Transistors Type Module Applied to all other

types

of module

As shown in Fig. 2.1., transistor

chopper

circuit requires at least six transistors.So

whenthe

six

transistors packed

type

module is used,

only

one transistor module is used.

But in the case of two transistors packed type modu Ie, at least three transistor modules are

required and t he number of the transistor modules used in th e circuit depends on the output

rated

current of the

inverter because

of the

parallel

connection

of transistor modules.

B B 4 8 ~ 7

Fig. 6,,5.3 Outlook of Six Transistors Packed

Type

Module

29

B 8 4 B ~ 9

Fig. 6 5 4 Outlook of Two Transistors Packed

Type Module


32/128


2 Inspection and checking

of

transistor module

As the power transistor is connected in the Darlington

Connection

as shown in Fig. 6.5.5, the

inspection result is a little different

from

one of a usual transistor. So, inspect the power

transistor in the following manner.

c

o

E

Fig. 6.5.5 Darlington Connection of Power Transistor

a Power-on inspection

Under the condition of the driving of the inverter, inspect and check the voltage waveform

between the em itter E and the base B . I f the power transistor is in its normal operat ions, the

inspected waveforms is l ike Fig. 6.5.6 a . I f i t is

no t

normal, the arnblitude of the waveform

is somehow lower than the normal one as shown in Fig. 6.5.6 b .

l:VI_

~

1.3

[

a normal

about

1 o 0 ~ r - - - - - - ~ ~ / T h e

amplitude

becomes lower than

the normal one,

b abnormal

Fig. 6.5.6 B-EWaveform of Power Transistor

CAUTION

Be careful

not

to touch any conductive parts of the inverter during the power on inspection.

Electrical shock may cause a serious injury

b Power-off inspection

Take

ou t

the power transistor to be inspected and check via the

following

Fig. 6.5.7.

5 Kn or more

5 Kn or more more than n more than n

less

than

5 n less

than

soon

Fig. 6

5.7 Checking of Normal Transistor

less

than 5 n

Note:

Use silicon compound between the transistor and the heatsink at the replacement the

transistor

3


33/128


For details

o th

types of power transistors refer

to

Table 6 5

Inverter type

Type

of

transistor

Quantity

F R F2 750B U OM15TC H BKO C1982H02

1

FR F2 1500B U

OM20TC H BKO C1982H03 1

FR F2 750 U

OM15TB H BKO C1905H03 1

FR F2 1500 U

OM20DX H BKO C1869H02

3

FR F2 2200 U

OM50DY H BKO C1869H03 3

FR F2 3700 U OM50DY H BKO C1869H03

3

FR F2 5.5K U OM50DY H BKO C1869H03

3

200V

l ss

FR F2 7 5K U OM100DY H BKO C1819H02 3

FR F2 11K U OM150DY H BKO C1945H01 3

FR F2 15K U


FR F2 22K U


FR F2 30K U

OM150DY H BKO C1945H03

9

FR F2 37K U OM100DY H BKO C1819H04 12

FR F2 45K U

OM150DY H BKO C1945H03

9

FR F2 55K U

O M 5 D Y ~ H BKO C1945H04

12

FR F2 H3700 U OM25DY 2HA BKO C1851H02

3

FR F2 H5 5K U

OM50DY 2HA BKO C1851H03

3

FR F2 H7

5K U

OM5 DY HA BKO C1851H03

3

FR F2 H11K U


3

460V l ss

FR F2 H15K U


3

FR F2 H22K U


6

FR F2 H30K U


6

FR F2 H37K U OM100DY 2HA BKO C1851H04 6

FR F2 H45K U


9

FR F2 H55K U


9

Table 6.5 Type Designations

of

Power Transistors

31


34/128

ONTROL RD

7. CONTROL CARD

7 1 Card Application

The control card

type

F RF2-CB or CA and RF2-DR are applied in the

following

manner.

FRF2-CB Main control card

FRF2-DR Driver amplifier card fo r

230V

class inverter

FRF2-HR Driver amplifier card

fo r

460V l ss inverter

Inverter type

Type of control card

Type

of

driver amplifier card

FR-F2-750B-U FRF2-MA12

FR-F2-1500B-U FRF2-MA22

FR-F2-750-U

FR-F2-1500-U

FRF2-CB12 CA12)

Not used

FR-F2-2200-U

FR-F2-3700-U

FR-F2-5.5K-U

FRF2-CB32 CA32)

200V l ss FR-F2-7,,5K-U

FR-F2-11K-U

FR-F2-15K-U

FR-F2-22K-U FRF2-DR1

FR-F2-30K,U

FRF2-CB31 CA31)

FR-F2-37K U

FR F245K U

FRF2-DR2

FR-F2-55K-U

FR-F2-H3700-U

FR-F2-H5.5K-U

FR-F2-H7.5K-U

FRF2-CB36 CA36)

Not

used

FR-F2-H11K-U

460V

l ss

FR-F2-H15K-U

FR-F2-H22K-U

FRF2-HDR1

FR-F2-H30K-U

FR-F2-H37K-U

FRF2-CB35 CA35)

FRF2-HDR2

FR-F2-H45K-U

FR-F2-H55K-U

Table 7 1 Application

of The Control Card

32


35/128

7 ONTROL RD

Note: Each printed circuit board does not have any compatibility, Use exactly the same cards as listed in Table

7.1 at the replacement of the control card,

Note: The character UAU of FRF CA means the version of the control card and new version has the compati-

bility with

old

one,

FRF2 CA

12

and

FRF2 CB 2

is compatible

7.2

Basic Operation of

the Control

Card

The block diagram of FRF2-CB is shown in Fig. 7.1.

As shown in

the b lock

diagram,

the

speed command, the accel and decel sett ing signal or

other

signals are given

to

the microprocessor through

the

interface

circuit.

The microprocessor produces both the frequency command and the voltage command according

to the frequency command and the FIV pattern. These digital signals produced by the microproces

sor are converted

into the

pulse train signal by

the

read only memory ROM). These pulse

train

sig

nals are changed

into

the base

current

signal which is required

to

drive the main

circuit

transistor

module.

For inverters whose capacity is 15HP or more for 200V class)

of

30HP or more

for 460V

class),

the basic

current amplifying

card

type

FRF2-DR

for 200V

cl ss or

FRF2-HDR for 460V

class)

are provided.

According

to

the base cur rent signal, the main circuit transistor module converts the DC voltage

into the required PWM Pulse

Width

Modulation alternative voltage.

The DC-BUS current detected by

two

DC-CTs is given to the logic circuit lC BKO-C1921) together

with the DC-BUS voltage which is isolated by the IC BKO-C1913. Accord ing to the logic circuit

determined by the IC BKO-C1914, the stall prevention signal is given to the microprocessor and

other fau lt

signals Ground

fault,

overload, overcurrent

tripping,

overvoltaqe, and instantaneous

power failure) are activated.

The signal

from

the thermal sensor is also given to

this control

card This thermal sensor is

normally

colsed and mounted

to

the inverter 7.5HP or more

200V

class) and 10HP or more 460V class).

The block diagram of the p.c.b.,

FRF2-MA12

and

-MA22

for new type B series are the same as

FRF2-CA series, but as the power circuits of the inverter are mounted on the p.c.b., input trans

former, converter module, transistor module,

initial

inrush

current

suppress resistor,

contactor

and

two DC current transformers are also mounted on the same p c b But the smoothing capacitors are

not mounted on the p.c.b. . Therefore, the

type

and

the outollk

of those components and the inter

nal construction

of

B type FR-F2-750B-U and 1500B-U) are different from the all o ther FR-F2

series.

33

I


36/128

-

I

r -

- -10 tg:

u - -,

, -

l l '

V-- - -


37/128

7

ONTROL RD

7.3

Fault

Indicating Lamp

The functions of fault indicators are as listed below.

At

least one

of motor

inputleads U, V and W is ground-

ed. The

principle

of

the detection is

t ha t two

current

feedbacks

f rom two

DC-CTs are always checked. Once

GF (Ground fault)

the signal

from

one

of

DC-CTs goes

to half of the other

DC-CT;

i t

is determined

to

have a ground fault condi-

tion.

If the value

of

current is under 30 percent

of

in-

verter rated current, this GF detector does

not

work.

When the stall prevention works, this lamp lights up.

OL

(Overload)

The details

of the

stall

prevention are

mentioned

later. (8.1)

If the

output

current exceeded 165 of the inverter's

OCT (Overcurrent

trip

rated

output

current,

that

is defined as the over-

current and this lamp lights up.

OVT

(Overvoltage

trip

If

the DC-BUS voltage exceeded the DC-BUS's over-

voltage level, this lamp lights up.

IPF (Instantaneous power failure)

If

the momentary power fai lure is lOnger than 15msec

but shorter than

about 80msec, this lamp

lights up.

OCT

OVT

If

both

of these lamps

light

up in the same

time, i t

means

that

the

electronic

thermal

relay

worked

Light up in the sametime)

because of overloading.

Note: Only one lamp is provided f or two functions L and OCT In the se of OCT the lamp

remains

lit

But in the

se of OL

the lamp

will blink

35

I


38/128

SOME OPERATION PRINCIPLES OF THE TOTAL

SYSTEM

OF THE INVERTER ~ n n

0

8. SOME OPER TION PRIN IPLES OF THE TOT L SYSTEM OF THE INVERTER

8.1 Stall Prevention

(1) Stall prevention at the acceleration mode.

If while in

the

acceleration mode the output current exceeds

the

150 of the rated current of

the

inverter,

the

microprocessor activates

the

stall prevention. During this operation,

the

micro

processor stops increasing the output frequency and decreases it according to the set deceler

ation time slope until

the

output current goes down below 150 . When

th t current

gets back

below 150 , the microprocessor resumes its normal operation and

the

output frequency is

increased according to the slope of the accel-time setting.

During

the

stall prevention, the fault indicating lamp will blink.

If fault indicating lamp blinks during the acceleration, the accel-time sett ing must be pro

longed. If this setting is too short, overcurrent tripping (OCT) will occur.

(2) Stall prevention t the deceleration mode.

During deceleration, once

the

DC-BUS voltage exceeds the stall prevention level,

the

stall

prevention is activated. In

the

case of deceleration,

the

microprocessor does

not

reduce the

output

frequency. In this case

the output

frequency is kept

const nt

during

the

stall prevention

mode.

Like the case of the acceleration, if fault indicating lamp blinks during the deceleration,

the

decel-time setting must be prolonged.

(3) Stall prevention at the const nt speed operation

Even under

the

const nt speed operation, once

the

output current exceeds its 150 rating, the

output frequency is reduced according to the decel-time setting until the current comes down

below 150 . hus OCT is avoided, and as a result, the stall

of

the

motor

which is caused by

the

OCT or OVT can be prevented.

Fig. 8.1 shows

the

functioning of the stall prevention

36


39/128

SOME

OPERATION PRINCIPLES OF THE

TOTAL

SYSTEM OF THE

INVERTER ~ ~ n

0

F2

150

I

I

I

I

I

I

I I I I

I I

I I

Output frequency

I

I I I

I I

I I

I I

I :

I

I

I

I

I

I

I

I

I

I I I I

I

Output current

I

I

I I

I

I I

I

I

/

/

/

/

/

1/

I

I

I

I

I

I I I

I I I

I

I I

I I I

I I

I IDC BUS voltage I

- - J - - J r

- - -

I I I

I I

f

VD

Stall prevention

level

7 . l t . ~ t

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

IStali prevention I

I

I

I

I

I I

I

I

I

I

ON

I

I

L

-I

I I

.....

OFF

t

Acceleration

onstant

peed

Deceleration

ig 8.1 Stall Prevention Timing

hart

37


40/128

SOME OPERATION PRINCIPLES OF THE TOTAL SYSTEM OF THE

INVERTER

[fmaml ll

0

F

8.2 Electronic Thermal Relay

In almost every c ses the inverter is used with a conventional induction

motor

which is cooled by

th e fan instal led on the shaft of the

motor

Thus the cooling

capability

of the

motor

depends on the

speed of the rotor

If the motor is driven by the commercial power supply, since

it

is driven in a constant speed, this

cooling

capability

is no problem.

But

once the

motor

is driven by the inverter,

th e

given frequency

is changed from almost OHz up to a frequency higher than the commercial frequency. So, when th e

motor

is driven by the lo w frequency, the current which is given

to

th e motor must be reduced. In

this

c se

conventional thermal relay does

no t

work at all.

An d

a new device which replaces conven

t ional thermal relay must be introduced. The electronic thermal relay was developed fo r this pur

pose.

Current

( )

100 -

90

50

o

6 30

Fig. 8.2.1

urr nt

Reduction Characteristics of Motors

60

Hz

As shown in Fig. 8.2.1, the current of th e

motor

must be reduced when the operation speed is

lo w

The

motor

current is always given

to

th e microprocessor and protected according

to

th e operation

speed. Fig. 8.2.2 shows the current

( )

v.s. time characteristics of the electronic thermal relay.

For

this electronic thermal relay, 100 current is def ined by the rated current of the inverter. So, since

th e usual rated current

of

th e

motor

is d ifferen t from th at

of

the inverter, the potentiometer labeled

TH on the printed circuit board must be adjusted according to the

following

formula

5

ttl iti 0/ motor s

rated current 100

e mg POSI Ion = inverter s rated current x

38


41/128

8.

SOME

OPERATION

PRINCIPLES

OF THE

TOTAL

SYSTEM OF THEINVERTER ~ ~ r n n n o F2

The electronic thermal relay is valid

only

when a single

motor

is driven by the inverter. If two or

more motors are driven by one inverter, the potentiometer should be set

to

the full clockwise

position and the conventional thermal relay must be installed

to

each motor.

MIN

70

Ql

Ql

en

en

0

n

N

0

en

N

I

E

I

E

0

1)

0 0 1)

N

IJ:

N

I

N

I

I

I

0

0

g

0

0

N

N

N

60

Adjustable

range

?f

?f2

0

0

L )

0

50

240

180

Ql

E

.;:;

OJ

c

6.

o

;:: 120

60

o

Adjustable

range

100

Setting =

150165

rated current of motor

rated current of inverter

200

x 100

I

Output

current

( )

(100 means rated

current

of the inverter)

Fig.

8 2 2

Output Current vs. Tripping Time of Electronic Thermal Relay

ote Full right position

and

1 setting are the same

39


42/128

SOME OPERATION PRINCIPLES OF THE TOTAL SYSTEM OF THE INVERTER ~ [ a [ [ j ~

F

8.3 Ground ault Protection

FR F2 inverter is equipped with the ground fault protective function.

und

fault

lout

Tl

A A

V

DCCT2

I in

v

Ground

fault

Protective circuit

Gro

DC BUS

line

Fig. 8.3

Ground ault

Protective

ircuit

As shown in Fig. 8.3 two currents u t and I in are always checked and compared by the pro-

tective circuit in the printed circuit board.

When either

of

two currents goes

down

to half of the other the ground fault tr ipping is activated.

This pro tect ion is

not

fo r detection of ground leakage current in milli amps.

4


43/128

FUSING

9. U ~ I N

To

protect elements in the inverter,

it

is recommended to install semi-conductor protection fuses

fast acting fuses) at the input of the inverter. Specifications of fuses are listed in the Table. 7.1.

nverter

type

Fuse rated current

Device

t

In-rush

t

FR-F2-750B 750)-U,1500B 1500)-U 25 amps rrns) 413 A

sec, 23 A

sec,

FR F2 2200 3700 U

35 amps rms)

540 A

sec

182 A

sec,

FR-F2-5,,5K-U

60 amps rms) 4150 A

sec.

608 A

sec

FR-F2-7.5K-U 60 amps rms)

4150 A

sec

729 A

sec

FR-F2-11K-U 100 amps rrns)

6000 A

sec

973 A

sec

200V class

FR-F2-15K-U 125 amps rms)

6000 A

sec.

730 A

sec,


17000 A

sec

973 A

sec,


17000 A

sec

2919 A

sec,

FR-F2-37K-U

300 amps rrns)

36400 A

sec

3406 A

sec.

FR-F2-45K-U 350 amps rms) 80000 A

sec.

3893 A

sec

FR-F2-55K-U 400 amps rms) 80000 A

sec,

3865 A

sec

FR-F2-H3700-U 35 amps rms)

660 A

sec

115 A

sec.

FR-F2-H5,,5K, H7,5K-U 35 amps rms) 660 A

sec

228 A

sec

460V

class

FR F2 HllK H15K-U 75 amps rms)

6000 A

sec.

458 A

sec,

FR-F2 -H22K-U 110 amps rms) 6000 A

sec.

610 A

sec,

FR-F2-H30K, H37K-U 150 amps rms)

16500 A

sec.

915 A

sec.

FR-F2-H45K, H55K-U

200 amps rms)

16500 A

sec.

1524A

sec

Table 9.1 Specifications

of

Fuses

In the table, Device 1

t shows permissible 1

t of the diode in the converter, and In-rush 1

t

shows the amount of the

input

current caused by the smoothing capacitor at the power on. Thus

the fuse should be chosen following the criteria of the following formula:

1) Permissible t ofthe fuse> In-rush t

2) Melting

1

t

of

the fuse


44/128

1 POWER F TOR IMPROVING RE TOR

1 POWER F TOR IMPROVING RE TOR

As the input current

of

the inverter is different from the usual three phaseAC current, as shown in

Fig. 10.1, the

input

power

factor

is lower than 1.0. To improve the power factor, the power factor

improving reactor listed below can be used.

1 Cycle (20msec or 16.6msec.)

R-Svoltage

Phase R line current

Fig. 10.1

Input

Current Waveform of Inverter

Inverter type

Reactor rated current Inductance

Type

.

FR-F2-750-U (750B-U)

5 5 amps

9

mH

BKO-C1969-H02

FR-F2-1500-U (1500B-U)

9

amps

5.5 mH

BKO-C1969-H03

FR-F2-2200-U

13

amps 4.0

mH

BKO-C1969-H04

FR-F2-3700-U

22 amps. 2.2 mH

BKO-C1969-H05

FR-F2-5.5K-U

29

amps

1 7 mH

BKO-C1969-H06

FR-F2-7.5K-U

44 amps

1.1

mH

BKO-C1969-H07

200V

class

FR-F2-11K-U 58 amps. 0.84 mH BKO-C1969-H08

FR-F2-15K-U

81 amps.

0.6

mH

BKO-C1969-H09

FR-F2-22K-lj

120 amps.

0..4

mH

BKO-C1969-Hl0

FR-F2-30K-U

150 amps.

0 33 mH BKO-C1969-Hl1

FR-F2-37K-U

190 amps

0.25 mH BKO-C1969-H12

FR-F2-45K-U

230 amps. 0.21 mH

BKO-C1969-H13

FR-F2-55K-U

290

amps

0 17 mH

BKO-C1969-H14

FR-F2-H3700-U

12 amps.

7..4

mH

BKO-C1974-HOl

FR-F2-H5.5K-U

16 amps 5 6 mH

BKO-C1974-H02

FR-F2-H7 5K-U

23

amps.

4.0

mH

BKO C1974-H03

FR F2 HllK U

31 amps 3 0 mH BKO-C1974-H04

FR-F2-H15K-U

42

amps 2.3 mH BKO-C1974-H05

460V

class

FR-F2-H22K-U

58 amps.

1.7

mH

BKO-C1974-H06

FR-F2-H30K-U

76 amps. 1 3

mH

BKO-C1974-H07

FR-F2-H37K-U

95

amps

1.

0

mH

BKO-C1974-H09

FR-F2-H45K-U

115 amps. 0.84 mH

BKO-C1974-Hl0

FR-F2-H55K-U

147

amps 0.66 mH

BKO C 974 Hll

Table 10.1 Types

of

Power Factor Improving Reactor

42


45/128

RADIO INTERFERENCE NOISE

11 . RADIO INTERFERENCE NOISE

When the motor is driven by the inverter, high- frequency noise is radiated by the inverter. L ike

the power supply noise, this noise gives great inf luence on the frequency band

of

1OMHz or lower.

When this noise enters a radio receiver, noise may be generated

from

the radio. The following

explains methods of restricting the radio noise, propagation paths of it and measuring methods

of it .

Radio receiver

Transformer

200V

/400V power supply line

Fig Propagation Paths of Radio Noise

11.1 Propagation Path of Niose

Possible propagation paths of radio wave noise from the noise source

to

the hindered receiver are

mainly asshown in Fig. 11.1.

a Direct radiation

Noise which is

directly

radiated by the noise source as airborne wave and enters

the

antenna

or

circuit

of receiver.

b Direct transmission

Noise current wh ich is transmitted through the power cable and flows

into

the receiver.

c Radiation induction from power supply cable

Noise which has leaked

to

the power supply cable, is radiated from the

distribution

l ine, and

enters the receiver.

d Radiation

from

power cable

Noise

which

is radiated

f rom wir ing

between the inver ter and

motor

and enters the receiver.

11.2 Noise Measuring Method

a Measurement

of

noise terminal voltage

Method of measuring the strength of disturbing wave, which f lows

ou t

to the power supply

cable of disturbance generating equipment as disturbing wave voltage

of

the distribution cable

to which the equipment is connected.

The unit of measurement is represented in dB

1J

tV= OdB .

43

I


46/128

RADIO INT RF R N NOIS

b Measurement of noise field strength

Method of measuring the strength

of

electric field, which is radiated from the disturbance

generating equipment

to

the air ,

with

an antenna. The measuring distance between the equip

ment and antenna is specified 10 m or 3 m.

The

unit

of measurement is represented in dB 1p.V/m

=

OdB .

c There is another method

of

measuring disturbing electric power and discontinuous noise click

of

contact equipment depending on the type

of

noise.

As described above, the disturbing wave noises

differ

greatly depending on the differences of

propagation paths and the types of noise measuring methods. In order

to

compare the actual

damage

of

radio receiver by the disturbing wave, the measurement

of

noise field strength is the most

suitable

bec use

the propagation path a , c

or

d givesthe greatest influence.

11.3

e sures

Against Radio Noise

Radio noise can be reduced

by

the

following

methods:

a Connect the radio noise

filter

exclusively used

fo r FREQROL

FR-BIF

to

the inverter

input

power supply terminals R, S, T phases , and positively ground the grounding wire. This is

effective when the

wiring

distance between inverter and

motor

is short. Fig. 11.2

MCCB

Power

supply

Fig 2

Inverter

b Place the inverter inside a steel box

without

instrument ports or indicator l ight ports and

ground the steel box.

c Connect the noise filter

to

the I/O terminals of inverter, and place the inverter and cables in

ground pipe. Minimize the length

of

grounding wire and completely ground. Fig. 11.3

-

I I

I I

1

Power supply

Noise

filter

VVVF

inverter

Noise

filter

Fig 3

44


47/128

R DIO INTERFEREN E NOISE

Power supply I

Fig 11 4

11 4 The Type and

Outline

of

Filter

nv rt r

Dia5 hole

T FR BIF

fo r

200V

l ss

inverter

ype FR BIF H .for 460V class inverter

White

Red Blue

. .

I I I I

Green

W

4

Fig 11 5 Dimensions of Radio Interference Filter

Note: 1 Connect wiring

o f

the filter to

termin ls

of the inverter directly

nd

wire them as short as possible.

(2)

ffective

fo r the noise

lower th n 1

OM

z

(3) Earth

the

wire by the earthing res/stance of less than 100ohms

45

I


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12

PPLI TION OF INVERTER

12 .

APPLICATION OF INVERTER

12.1 Efficiency

and Heat Generation

Amount of

Inverter

The inver ter eff ic iency is the conversion efficiency

of

inverter and is obtained by the following

expression by use of the input power

of

inverter and the output power of inverter input power

of

motor :

I

.

o/c

Inverter output

power kWj 100

- Inverter output

power

x 100

nverter e IClency 0 Inverter

input power

(kW) x - Inverter output pQwer + Inverter loss s

As is obvious

from

the above expression, the inverter efficiency is determined by the lossof inverter

i tsel f. The loss generated by the inverter can be classified into loss s of transistor inverter section

(approx. 50 ), converter section (approx. 15 ), cooling fan (approx. 5 ), control

circuit

(5

to

15 ) and others AC reactor).

Among the above

loss s

the loss amounts of inverter section and converter section vary according

to load current and

control

method. However,

the

lossof control circuit is almost uniform irrespec

tive

of capacity.

Therefore, when the

motor

has a small capacity and light load, the inverter efficiency is low.

However, when the motor has a large capaci ty, the eff ic iency is 95 to 97 as shown in Fig. 12.1.

Although the loss of cooling fan is relat ively

little,

power isalways consumed. Therefore, when the

inverter is stopped fo r a long time, the inverter may be separated from the power supply

-

Inverter

efficiency

>

I

Overall efficiency-

:

,

0

>

60

o

c

Q) 50

o

;; :

Ui

4

70

1

80

90

o

2 3 4 7 5

1

15

2 4 5 6 75

Motor capacity (HPJ

Fig 12 1 Inverter Efficiency

Note: Inverter efficiency

Indicates efficiency

of

inverter single unit

Overall efficiency

Indicates a value inverter

efficiency

x motor efficiency

3 Above value is based on

motor

loadratio of 100

60Hz

46


49/128

Temperature rise deg

12.

PPLI TION OF INVERTER

12.2 Heat Generation

Amount of

Inverter and Cooling

of

Panel

The heat generation amount

of

inverter due to generated loss is as shown in Table 12.1. In the

design of control panel, it is required to set the panel interior temperature to less than the maxi

mu m allowable temperature

of

inverter unit. The rise

of

temperature inside the control panel can

generally be obtained by the following expression:

Lossgenerated by inverter + Lossgenerated by other instrument inside panel W

K1 x panel radiation surface area m

2

+ K2x ventilation air volume I/min

Temperature rise deg < panel ambient temperature t -inverter

unit

maximum allowable temperature t

where, K1, K2

=

constants determined by structure

of

control panel

Examples of inverter containing panels are shown in Table 12.1.

Enclosed

Dustproof

Type Control Panel with Fan

IP5X or NEMA12 IP3X or Fan Cooled NEMA1

Inverter Capacity

Loss Area required for General box dimensions

Box dimensions reference

at rating radiation

unit:

inch

unit:

inch

FR-F2-750 750B -U

102W

1 98 m

2

15 7W x 15.70 x 39.4H

FR-F2-1500 1500B -U

130W

2.52 m

2

15

7W x 15..70 x 55 1H

FR-F2-3700-U

195W

3.78 m

2

mitsubishi freqrol f2 service manual

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